Ore-reducing furnace and process.



ORE REDUCING FURNACE AAAAAAAAA S.

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ORE REDUCING EURNACE AND PROCESS. AmilcATloN FILED FB. z. 915.5 RENEwEnNov. 2.1918.

LSS. Patented Dec. 31, 1918.

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JOHN T. JONES, OF MARQUETTE MICHIGAN, ASSIGNOR TO NEW METALS-PROCESSCOMPANY, OF CHICAGO, ILLINOIS, A CORPORATION OF ILLINOIS.

ORE-REDUCING FURNACE AND PROCESS.

Specication of Letters Patent.

Patented Dec. 31, 1918.

Application led Februaryv23, 1915, Serial No. 9,908. Renewed November 2,1918. Serial No. 260,913.

To all whom t may concern.

Be it known that I, JOHN T. JONES, a citizen of the United States,residing at Marquette, in the county of Marquette and State of Michigan,have invented a new and useful Ore-Reducing Furnace and Process, ofwhich the following is a specification.

The present .invention relates to furnaces adapted to the practice of abathless method of recovering metals from metal oXid or carbonate ores,or the like. The improved furnace is adapted to the practice of animprovement upon the process described in the application of John M.Longyear and myself, No. 9,889, filed in the United States Patent Oiceof even date herewith, the process referred to constituting animprovementV upon the process set forth in the application of Albert G.Jones, No. 827,358, filed March 26, 1914.

The present invention is illustrated in its preferred embodiment in theaccompanying drawings, in which- Figure 1 represents a broken verticalsectional view of an ore-reducing furnace constru'cted in accordancewith the invention, the section being taken as indicated at line l ofFig. 2; Fig. 2, a plan section taken as indicated at line 2 of Fig. l;and/Fig. 3, an enlarged broken, vertical section taken as indicated atline 3 of Fig. 2.

In the construction illustrated, A represents a furnace-shaft comprisinga soakingpit A', a superposed de-oxidizing chamber A2, and a pluralityof superposed pre-heating chambers A3, A4; B, B, a plurality of seriesof adjustable twyers extending through the side walls of the furnace anddisposed at a plurality of different levels; C, C, standpipes which maycontain air under small pressure, the air being supplied by a fan orcompressor C; C2, laterals extending from the stand-pipes andcommunicating through pipes l with the adjustable t-wyers B, the pipes 1being provided with regulatingvalves la; D, D, means for charging amixture of distilled solid fuel (coke or charcoal) and ore-portionssubstantially isolated therein into the upper portion of the furnace;and E, means for charging fresh solid fuel containing hydrogen andhydro-carbons (coal or wood) directly into the de-oXidizing chamber A2.,y

The furnace-shaft A may be of any suitable construction and of anydesired shape. It is preferred to make the furnace-shaft of rectangularcross-section, the width of the shaft being relatively small and thehorizontal length of the shaft being as large as desired, depending uponthe capacity desired. The internal short dimension of the shaft may bevfour to eight feet. One lateral wall of the furnace-shaft is providedwith a series of internal projections 2, and the other lateral Wall ofthe furnace is provided with a series of internal lateral projections2a, which are staggered with relation to the projections 2; that is, theprojections 2 are disposed at a'plurality of levels, and the pro-l thelower walls of the projections are underj cut. lThe result is to providean npr-ight zig- -zag channel of substantial, but relatively narrow,width, andv of comparatively large horizontal length, giving somewhatthe effect of a great rectangular chimney with a single upright zig-zagform passage adapted to contain a stack of superposed burden-sections ofa comparatively few feet in thickness corresponding with the horizontaltransverse dimension of the furnace-shaft, and of a comparatively-'largehorizontal length, corresponding with the long horizontal dimension ofthe furnace-shaft. rlhe internal projections of the furnace-shaft are ofsuch substantial character as to almost, but not quite, support theburden-sections, the purpose being to prevent undue compacting of thematerials in the furnace and the crushing of the distilled fuel, whichwould interfere with the practice of the bathless metallizing process.rlhe adjustable twyers B are associated with the internal projections ofthe lateral walls of the furnace, and may extend a greater or lessdistance into the furnace, being adapted to aord supplemental supportsfor the burden-sections, as well as to introduce air into theburden-sections at a plurality of levels. The twyers are so adjusted Ias to permit a slow downward gravitation ofv the burden-sections; andthe internal 'pro- -jections of the furnace walls arel so limited andsloped as to permit this action to occur,

while preventing the direct transmission of solid fuel, gangue, andmetals in solid form,

may be discharged into water-baths 5. The discharge means illustrated isto be regarded as a conventional form of any suitable dis' charge means.

The means D shown for introducing distilled solid fuel (coke orcharcoal) and ore into the upper portion of the furnace compriseshoppers having chutes 6 extending through the lateral walls ofthefurnace, the hoppers being equipped with closures 7 The devices D aretoy be regarded as conventional examples of any suitable means forintroducing solid fuel and ore into the upper portion of the furnace.

The means E comprises a hopper or ho pers, and it is to beunderstoodthat such form is selected merely for the purpose of illustration.

Assuming the furnace to bein operation, the stack of materials fills thefurnace from the bottom to the chutes 6, thus forming a afforded by theru imentary staggered botv toms 2, 2, which, while sufficient to preventthe transmission of crushing 'stress from the top to the bottom of thefurnace, will nevertheless permit the slow settling of the stack oflmaterials as materials are withdrawn from the bottom of the furnace.The stack -of materials is replenished by the proper charges lofdistilled solid fuel and ore-portions substantially isolated therein,introduced througlh the charging-devices D at the top of the rnace; andthe supply of distilled solid fuel is replenished 'by fresh solid fuelintroduced through the charging-device E directly into the deoxidizingchamber A2, it being understood that the fresh" Solid fuel. supplieswithin the de-oxidizing chamber hydrogen gas Aand carbo-hydrates whichare highly efficacious in the metallizr -ing operation, while thedistilled Solid fuel which is thus produced serves as a constantsfplu'ce forreplenishment of dist-illed solid Air is supplied throughthe lowermost twyers to the chamber A2.in limited quantity, butsuiicient to produce in the chamber A2 a high-tem erature de-oxidizingmedium and a metalxing zone. The temperature in the lower portion of thechamber A2 should exceed 2000 F. for iron, and usually a temperature'of3000 F. is ample for re ducing iron-ores, ferro man,=,vanesev ores, andthe like. .Much depends upon the character of the ore, however. ndealing with lean ores containing some natural iux, too high atemperature is desirably avoided. T he air i supplied at the otherlevels of the furnace is so regulated as to afford a progressivereduction in the temperature as the top of the furnaceA is approached,somewhat as indi` catedby the temperature-scale Shown .on Fig. 1. Itwill be understood that a zone of intense heat is produced inthevicinityof the inner ends ofthe lower twyers and that the carbondioxid produced in that zone changesto carbon monoxid as the gasesascend inthe chamber A2. Owing tothe hightemperature maintained in thechamber A2,

a rapid interchange 'of oxygen occurs, and' the metal ores are rapidlyrobbed of their oxygen, and asthe metalhzingoperation proceeds, themetals are fused, or partially fused, and agglomerated or run together,-`thus producing metal bodies of tangible size, ranging from small meshesto large chunks. Inasmuch as-theore-clusters are substantially isolatedin the solid fuel, the

production of a bathis avoided, and the metal freezes as itdescends tothe chamber A. Isolated pools of metal may be produced, and likewiseisolated pools of gangue, especially where the ore contains a naturaliux, may be produced, which will congeal as the'ore descends. No lime orother flux need be introduced with the charge, however, 'as generalfusing ofthe chargeistobe avolded.

It will be understood that somewhat in-` tense zones of heatV will beproduced at the inner ends of the several series of twyers, the heat inthese zones becomlng of less and less ico intensity as the upper end ofthe furnace isA that the solid fuel is attacked less and less as theupper end. of. the furnace 1s approached, and {inally the combustiblegasesA produced b elow are burned with the .air introduced through theupper twyers, 1n contact with the entering fuel and ore, and thusserving to preheat thesematerials,without' atapproached. "Thus, it willbeY understood tackng the solid fuel, the products of combe burned to astate of-complete combustion,

under .ideal conditions. As anillustration,

ortions, will be carried wholly through the in dealing with a high-gradeiron ore, the materials may be used in the proportion of 400 pounds ofcoke, 100 pounds of bituminous coal, and 25() pounds of ore, the fuelhaving approximately twice the weight of the ore and being approximatelyfive times as large in volume as the ore. If wood and charcoal be usedin place of coke and coal, the disparity in volume is much greater. Forillustration, with 2240 pounds of ore one may use 96 cubic feet ofcharcoal and 32 cubic feet of wood. The proportions may be variedto gainthe best and most economical results. In any case, it is preferred touse the fuel mainly in large block or lump form, although this is notindispensable. The coke (or charcoal) is used over and over again, beinggradually reduced in size but being` constantly replenished by freshlyformed coke (or charcoal) when the process is carried on in thepreferred manner.

The separation of the metals, gangue and distilled solid fuel, afterremoval from the bottom of the furnace, may be effected in any desiredmanner.

In practice, the method of feeding materials to the furnace may bevaried, according to conditions. 1f green or wet wood be used for fuel,it may be fed in at a higher level, so that the water will be driven oifbefore the wood reaches a lower and hotter zone. ln such case, the woodwill be thoroughly dried and somewhat charred during the pre-heating,the volatile hydro-carbone being mainly liberated at a ,flower l:levelwhere they can be utilized most effectively. In some cases, it may bedesirable to feed all or a large portion of the fuel in at a lower levelthan that at which the ore is fed."

Much will depend upon the character of the ore and the solid fuel used.ln any event, it will be necessary to maintain suficient interstitialpassages for the air and gases through'the burden; and it will benecessary to maintain a large preponderance of solid fuel in the lower,hotter zone.

The foregoing detailed description has been given for clearness ofunderstanding only, and no unnecessary limitation should be understoodtherefrom, but the appended claims should be construed as broadly aspermissible in view of the prior art.

lihat l regard as new and desire to secure by Let-ters Patent is- 1. Anore-reducing furnace having walls forming a tortuous upright passageadapted to contain a stack of solid fuel and ore-portions isolatedtherein and afford supports at intervals for the burden-sections, andtwyers disposed at a plurality of levels and adapted to supply air insuch limited quantities to the burden-sections as to produce adeoxidizing atmosphere. 2. An ore-reduclng furnace comprisingsoaking-pit equipped at its lower portion with means for removing'unconsumed solid fuel, gangue and metal in solid form, a

superposed de-oxidizing chamber, means for charging fresh solid fuelinto the deoxi'dizing chamber, superposedpre-heating chambers havingwalls provided with staggered internal projections, twyers disposed at aplurality of levels and serving to furnish limited air-supplies to thepre-heating chambers, andmeans for charging distilled solid fuel andore-portions mixed therein into the upper portion Aof the furnace.

4. An ore-reducing furnace comprising a soaking-pit provided withdischarge means, a superposed de-oX-idizing chamber with a contractedpassage between said chambers, means for supplying air to thede-oxidizing chamber, a series of pre-heating chambers above thede-oxidizing chamber, the walls thereof having internal projectionsarranged lin staggered relation, a plurality of series of twyersarranged at a plurality of levels for supplying air to the pre-heatinrchambers, and means for charging solid uel and ore into the upperportion of the furnace.

5. In an ore-reducing furnace, the combination of a shaft provided witha series of internal staggered burden-section supports, adjustabletwyers disposed at Aa plurality of levels and associated with saidinternal supports,`means for supplying air in limited quantities to saidtwyers,and means fory charging solid fuel and ore mixed therei into theupper end of the furnace.

6. 1n an ore-reducing furnace, the combination of a shaft provided withside walls spaced a few feet apart and provided with end walls, internalprojections carried by the side walls and arranged in staggeredrelation, a series of horizontally arranged. adjustable twyersassociated with the internal projections'at diiferent levels, means forsupplying air in regulable quantities to said twyers, and means forcharging solid fuel andere into ,the upper. portion of kthe furnace. I l

7. The fbathless process of metallizing ores, which consists insupporting burdensections composed of solid fuel and oreportionssubstantially isolated therein, in

aiczd substantially independent support to the burden-sections and eiectturning mixing 'of the materials as the stack settles slowly,introducing and burning in the 5 lower portion of the stack air in suchquantity as to produce a high temperature metalfixing zone and a hightemperature de-oxidizing medium aibove said zone, and intro?.

ducing and burning air in limited quan- 10 tities at a plurality ofhigher levels in and,

such manner as to attack `the solid fuellessvand less as the upperportion of the stack is approached, finally burning thecombustible gasesto a state of practically complete com at the upper portion of thestack.

JOHN T. JONES. In the presence of- ALBERT G. JONES, E. W. JONES.

ustion Without attacking the solid-fuel 15

